Optimal

Optimal Boiler
Boiler Size
Size
and
and its
its Relationship
Relationship to
to
Seasonal
Seasonal Efficiency
Efficiency

Henry Manczyk, C.P.E., C.E.M.

Director of Facilities Management
Monroe County, Rochester, N.Y. December 20, 2001
 OPTIMAL BOILER SIZE AND ITS RELATIONSHIP TO
SEASONAL EFFICIENCY

TABLE OF CONTENTS

Introduction
-Seasonal Efficiency
-Optimal Sizing
-Modular Boiler System
-Estimating the Annual Runtime of a Boiler System
-Conclusion
Appendix
Total Bin Hours in the Range of 0oF 59oF
Total Available Hours During Heating Season (Sept. 1 May 1.)
Percentage of the Total Season That an Optimally Sized Boiler Will Operate
Calculation Data for Degree-Hours at 70 oF
Calculation Data for Degree-Hours at 60 oF
Bin Hour Multiplier Or the Percentage of Each Shift at Each Temperature
Calculation for Run Time Hours
The Effect of Oversizing a Boiler on the Percentage of Boiler Run Time
Oversized Boiler Equations
Percentage of Boiler Full Load Versus Outdoor Air Temperature
An Empirical Equation to Determine Efficiency on Boilers at Different Loads
Determining Efficiency of Oversized Boilers
Rochester Region Climatological Data
Monthly Heating Bin Hours per Shift
Bin Hours Summation from Sept. 1 to May 1.
 Optimal Boiler Size and Its Relationship To Seasonal Efficiency
By: Henry Manczyk, C.P.E.,C.E.M.

INTRODUCTION

In addition to installing high efficiency boilers and maintaining them in good condition, facility
managers can employ other strategies to ensure that a heating plant serves the facility efficiently.
These include ensuring that the system is optimally sized and that the system operates at an output
that is appropriate for the demands of the facility throughout the heating season.

Most heating boilers are designed to operate at maximum efficiency when producing their rated
heat output in Btu/hr. Since most boilers only operate at 60 percent or less time at their rated
capacity for 90 percent of the heating season, boiler seasonal efficiency is significantly reduced
and primary energy resources are wasted.

Seasonal efficiency in a boiler can be improved in several ways. This discussion focuses on three
methods: Ensuring that the boiler system is optimally sized to the demand of the facility based on
established outdoor temperature and the standard indoor design temperature of 70F at which
most people feel comfortable; use of a modular system of boilers to meet that demand since the
fuel economy drops off rapidly as the demand versus boiler maximum heat output falls; and the
calculations used to evaluate the seasonal efficiency of the system. The calculations will evaluate
how the use of a night setback on the heating system affects the boiler overall run-time and its
seasonal efficiency.

SEASONAL EFFICIENCY

Seasonal operating efficiency is the ratio of the total seasonal heat output actually used by the
facility to the total seasonal fuel input. This efficiency is dependent on the boiler's steady-state
efficiency, standby losses, and cycling losses, all of which constitute the Total Seasonal Input.

Seasonal efficiency = Total Useful Seasonal Output/Total Seasonal Input

1
Since most boilers operate most efficiently at full capacity, the longer a boiler operates at full
capacity, the higher the seasonal efficiency. When a boiler shuts off, the heat in the boiler
continues to radiate through its jacket. In addition, boiler-room ambient air continues to flow
throughout the boiler after the burner shuts off. When the boiler turns on again, it must reheat the
boiler medium to the operating temperature or pressure. A boiler that is smaller than required will
more closely match the heating load of the building for a larger part of the season because of
fewer on and off cycles. The more often the boiler cycles, the greater the amount of heat would be
wasted. (See the Weil-McLain website, http://www.weil-mclain.com/netdocs/straighttalk.num .)

OPTIMAL SIZING

Boiler systems must be optimally sized to meet the maximum facility demand during the normal
heating season. Essentially, the system must provide the heat output required to meet the facility's
total demand at the lowest expected temperature of the heating season. Systems that are sized
beyond the optimal output capacity, (oversized) boilers, will have lower seasonal efficiency.
Properly sized boilers will also reduce maintenance costs by starting and stopping less frequently.
Oversized boilers waste fuel and, because of short cycling, ultimately shorten the life of the
system. (The "Oversized Boiler Equations" section of this article shows calculations that permit
one to determine the extent to which a boiler is oversized.)

Optimally sized equipment operates more efficiently by cycling properly, thus saving fuel. A U.S.
Department of Energy Office of Industry Technoloyies "Energy Tips" report discusses this (see
"Minimize Boiler Short Cycling Losses". (http://www.oit.doe.gov/bestpractices ).

A boiler cycle consists of a firing interval, a post-purge, an idle period, a pre-purge, and a return
to firing. Boiler efficiency is the useful heat provided by the boiler divided by the energy input
(useful heat plus losses) over the cycle of duration. Boiler "short cycling" occurs when an
oversized boiler prematurely satisfies space heating demands and then shuts down until heat is
again required. Efficiency decreases when short cycling occurs because heat demand is smaller
than the boiler output.

2
This decrease in efficiency occurs in part because fixed energy losses are magnified under lightly
loaded conditions. For example, if the radiation loss from the boiler enclosure is 1% of the total
heat input at full load, at half load the losses increase to 2%; and at one quarter load, the loss is
4%.

Standby Losses Report published by Tri-State Generation and Transmission Association, Inc
(http://tristate.apogee.net/et/ehubsbl.htm) states that about 1.5% to 2.0% of rated boiler fuel input
is lost to the boiler room. While this "standby loss" is small in comparison to useful output when
boilers operate at or near their rated capacity, it can be significant where boilers operate
frequently at low loads. For example, imagine a boiler rated at 10 million Btu/hr fuel input, but
operating at a 2 million Btu level. The standby loss of 2% of 10 million Btu is 200,000 Btu/hr, or
10% of the 2 million Btu operating output level. This is the reason why plants with large summer
to winter variations in steam use install small boilers to operating during the summer rather than
operate large boilers year round.

One can also avoid short cycling by adding small boilers to a boiler facility to provide better
flexibility and high efficiency at all loads. (This strategy is discussed in "Modular Boiler Systems,
below.) Consider when one boiler with a seasonal efficiency of 73% (E1) is replaced with three
modular boilers resulting in a seasonal efficiency of 79% (E2).

The Annual Fuel Savings

E E1 0.79 0.73
AFS = 2 (100% ) (100) = 7.6%
E2 0.79

E1=Seasonal Efficiency with One Boiler

E2=Seasonal Efficiency with Three Boilers
AFS=Annual Fuel Savings

If the original boiler used 100,000 MMBtu of fuel annually, the savings from switching to smaller
boilers given a fuel cost of $5.00/MMBtu is calculated as follows:

3
 Annual Cost = (Annual fuel consumption)(Annual Fuel Savings)(Cost/MMBtu)
(100,000 MMBtu)(0.076)($5.00) = $38,000

Savings at this level can yield a payback period for the new or modified boiler system of less than
one year which could be financed directly from operating budget savings resulting from the new
system.

MODULAR BOILER SYSTEM

Seasonal efficiency can be increased by replacing a single boiler with a network of smaller
modular boilers, as shown below. Since modular boilers can be fired independently each module
would be fired on demand at 100 percent capacity with load fluctuations being met by firing more
or less boilers. When the first boiler can no longer keep up with the heat demand, a second boiler
picks up the extra heat load. Also, modular boilers have low thermal inertia which provides rapid
response and low heat-up and cool-down losses.

Outdoor temperature fluctuations during the heating season reduce the seasonal efficiency of even
optimally sized boilers and boiler systems. There are relatively few periods during the heating
season when it will be running at its rated output or point of maximum efficiency.

4
The following demonstrates that the percentage of run-time for a optimally sized boiler is less if
there is a temperature set-back during the unoccupied hours than if the building were to be kept at
a constant temperature throughout the heating season.

ESTIMATING THE ANNUAL RUNTIME OF A BOILER SYSTEM

Estimating the annual runtime of a boiler system is important in assessing whether to use a large,
single boiler or several smaller. modular units to optimize seasonal efficiency of the system. It is
based on estimating the annual heat loss of a building and dividing that by the hourly output of the
boiler system.

Heat Loss Calculation Method

To estimate the runtime of a boiler system a practical method of estimating heat loss is being
utilized, called the Bin Method.

The Bin Method is the summation of the total heat loss at each given average Bin temperature for
a year. A Bin is a 5F spread of temperature, for example, 55F to 59F, where there are 26 Bins
from 100F to -30F, and these Bins are usually referred to by their average temperature Bin
57F is 55F to 59F. One Bin hour is formed when the outside temperature stays for one hour
inside a Bin (one Bin hour at the 57F Bin requires the temperature to be between 55F and 59F
for one hour). Therefore, all 8,760 hours of the year can be accounted for with an outside air
temperature in the 26 Bins--100F to -30F (continental United States).

A Bin hour table is split into three eight-hour shifts 12:30 a.m. to 8:30 a.m., 8:30 a.m. to 4:30
p.m. and 4:30 p.m. to 12:30 a.m. This recognizes that facilities often have different desired
indoor temperatures during different operating shifts.

When using the Bin hour table for heat loss estimation, the average Bin hour temperature is
subtracted from the desired indoor temperature for the shift, and the difference is then multiplied

5
by the hours in the Bin, or the hours in the portion of the Bin needed. This is then multiplied by
the heat loss per hour per degree, and the heat loss amounts in each of the Bins are totaled to
obtain the total heat loss. This is a more accurate method of calculating the heat loss for a whole
year, or any portion of the year.

Runtime Comparison, with vs. without Setback

The following section is a detailed calculation comparing the runtime of an optimally sized boiler
system with and without a night setback. The comparison uses Bin hour data for the average
heating system for the Rochester, New York, area for a system operating for a single shift,
Monday through Friday. It shows that the night setback reduces the system runtime for both
optimally and oversized boiler systems by up to 10%.

CONCLUSION

Controlling heating costs for a facility doesn't only involve incorporating efficient boilers and
optimizing fuel utilization in the heating system and maintaining the facility itself efficiently. It
also involves how the heating system itself is designed and how it is used. This article has shown
that carefully sizing the boilers to the heating demand of the facility, designing flexible, modular
boiler systems, and incorporating features such as setback temperatures in the system can
significantly contribute to seasonal boiler efficiency improvement, thus reducing the operating
cost of the system.

6
References

Much of the information in this report is based on articles prepared by:

Minimize Boiler Short Cycling Losses (see website,

www.oit.doe.gov/bestpractices)
By: US Department of Energy Office of Industry Technologies

Straight Talk about Boiler Efficiency (see website, www.Weil-

McLain.com/netdocs/straighttalk.num) By: Weil-McLain

Standyby Losses (see website, http://tristate.apogee.net/et/ehubsbl.htm)

By: Tri-State Generation and Transmission Association, Inc.

Energy Management with Commercial Hydronic Heating Systems

By: Weil-McLain

Boiler Efficiency By: Weil-McLain

Niagara Falls, N.Y. Climatological Data (1985)

Weather Information from Niagara Falls, IAP New York

The author has developed further analysis on these concepts in the

attached appendix.

7
Appendix
 Rochester, N.Y. Region
Total Bin Hours in the Range of 0oF - 59oF

SHIFTS
MID- TOTAL
RANGE 00:30 - 08:30 08:30 - 16:30 16:30 - 00:30
POINT HOURS

59-55 57oF 96 143 125 364

54-50 52oF 137 143 159 439

49-45 47oF 167 157 179 503

44-60 42oF 197 181 188 566

39-35 37oF 254 238 253 745

34-30 32oF 345 276 307 928

29-25 27oF 227 185 213 625

24-20 22oF 152 117 133 402

19-15 17oF 106 60 81 247

14-10 12oF 74 39 59 172

9-5 7oF 39 13 20 72

4-0 2oF 12 5 6 23

Total Hours in the Range 5,086

of 0oF - 59oF

NOTE! It is assumed that, with the building improvements, energy

is not consumed at an outside air temperature of 60oF or above.

8
 TOTAL AVAILABLE HOURS DURING HEATING SEASON
FROM
SEPTEMBER 1 TO MAY 1

MONTH DAYS HOURS

September 30 720

October 31 744

November 30 720

December 31 744

January 31 744

February 28 672

March 31 744

April 30 720

TOTAL AVAILABLE HOURS = 5,808

9
PORTION OF THE TOTAL HEATING SEASON

(September 1 May 1)

THAT AN OPTIMALLY SIZED BOILER WILL

OPERATE WITH AND WITHOUT A NIGHT

SETBACK TEMPERATURE

10
 PERCENTAGE OF THE TOTAL SEASON THAT A OPTIMALLY SIZED

BOILER WILL OPERATE WITH A NIGHT SETBACK TEMPERATURE

(1) Equation for heat loss from a building

Q = H.L.M. x T
Where
Q = Btu/Hr
H.L.M. = Heat loss multiplier = U-factor x Area = BTU
(Hr - oF)

T = Temperature difference
= Indoor design temperature outdoor temperature

(2) Equation for total heat loss for a heating season using the Bin Hour method.
Q = H.L.M. x T x Hour
Where
Q = Btu
H.L.M. = Heat loss multiplier = U-factor x Area = BTU/(Hr - oF)
T = Temperature difference
= Indoor design temperature outdoor temperature
Hour = Bin Hour

NOTE: The bin hours are the length of time that the outside air temperature is between a given
temperature range. The Bin temperature used in these calculations are the mid-point of the given
temperature range.

11
The total heat loss for a season with a constant indoor temperature of 70 oF is:

Q = H .L.M . x (T 2 T 1 ) x Hours

This can be written mathematically:

Total Heat Loss = H .L.M . x T ( Bin Hours )

Where,

T (Bin Hour) is the summation of each T times the corresponding bin hours for the heating season.

At 70 oF the T (Bin Hour) is:

o
( 70 - 57 ) x 364 Hour = 4,732 F-Hr
( 70 - 52 ) x 439 = 7,902
( 70 - 47 ) x 503 = 11,569
( 70 - 42 ) x 566 = 15,848
( 70 - 37 ) x 745 = 24,585
( 70 - 32 ) x 928 = 35,264
( 70 - 27 ) x 625 = 26,875
( 70 - 22 ) x 402 = 19,296
( 70 - 17 ) x 247 = 13,091
( 70 - 12 ) x 172 = 9,976
( 70 - 7 ) x 72 = 4,536
( 70 - 2 ) x 23 = 1,564
o
175,238 F-Hr

12
 CALCULATION DATA FOR DEGREE-HOURS AT 70 oF

Heat Loss Multiplier: 1 Btu/(Hr.- oF)

Occupied Building Hours:

Monday-Friday: 8:00 a.m. to 5:00 p.m.

Occupied indoor temperature set at 70 oF

Unoccupied indoor temperature set at 60 oF

T (Bin Hour)

T 70 oF 01 to 08 Hours
o
( 70 - 57 ) x 96 Hour = 1,248 F-Hr
( 70 - 52 ) x 137 = 2,466
( 70 - 47 ) x 167 = 3,841
( 70 - 42 ) x 197 = 5,516
( 70 - 37 ) x 254 = 8,382
( 70 - 32 ) x 345 = 13,110
( 70 - 27 ) x 227 = 9,761
( 70 - 22 ) x 152 = 7,296
( 70 - 17 ) x 106 = 5,618
( 70 - 12 ) x 74 = 4,292
( 70 - 7 ) x 39 = 2,457
( 70 - 2 ) x 12 = 816
o
64,803 F-Hr

13
T 70 oF 09 to 16 Hours
o
( 70 - 57 ) x 143 Hour = 1,859 F-Hr
( 70 - 52 ) x 143 = 2,574
( 70 - 47 ) x 157 = 3,611
( 70 - 42 ) x 181 = 5,068
( 70 - 37 ) x 238 = 7,854
( 70 - 32 ) x 276 = 10,488
( 70 - 27 ) x 185 = 7,955
( 70 - 22 ) x 117 = 5,616
( 70 - 17 ) x 60 = 3,180
( 70 - 12 ) x 39 = 2,262
( 70 - 7 ) x 13 = 819
( 70 - 2 ) x 5 = 340
o
51,626 F-Hr

T 70 oF 17 to 24 Hours
o
( 70 - 57 ) x 125 Hour = 1,625 F-Hr
( 70 - 52 ) x 159 = 2,862
( 70 - 47 ) x 179 = 4,117
( 70 - 42 ) x 188 = 5,264
( 70 - 37 ) x 253 = 8,349
( 70 - 32 ) x 307 = 11,666
( 70 - 27 ) x 213 = 9,159
( 70 - 22 ) x 133 = 6,384
( 70 - 17 ) x 81 = 4,293
( 70 - 12 ) x 59 = 3,422
( 70 - 7 ) x 20 = 1,260
( 70 - 2 ) x 6 = 408
o
58,809 F-Hr

14
Therefore: at 70 oF the T (Bin Hours) =

01 to 08 = 64,803

09 to 16 = 51,626

17 to 24 = 58,809

Total = 175,237 oF-Hr

15
 CALCULATION DATA FOR DEGREE-HOURS AT 60 oF

T 60 oF 01 to 08 Hours
o
( 60 - 57 ) x 96 Hour = 288 F-Hr
( 60 - 52 ) x 137 = 1,096
( 60 - 47 ) x 167 = 2,171
( 60 - 42 ) x 197 = 3,546
( 60 - 37 ) x 254 = 5,842
( 60 - 32 ) x 345 = 9,660
( 60 - 27 ) x 227 = 7,491
( 60 - 22 ) x 152 = 5,776
( 60 - 17 ) x 106 = 4,558
( 60 - 12 ) x 74 = 3,552
( 60 - 7 ) x 39 = 2,067
( 60 - 2 ) x 12 = 696
o
46,743 F-Hr

T 60 oF 09 to 16 Hours
o
( 60 - 57 ) x 143 Hour = 429 F-Hr
( 60 - 52 ) x 143 = 1,144
( 60 - 47 ) x 157 = 2,041
( 60 - 42 ) x 181 = 3,258
( 60 - 37 ) x 238 = 5,474
( 60 - 32 ) x 276 = 7,728
( 60 - 27 ) x 185 = 6,105
( 60 - 22 ) x 117 = 4,446
( 60 - 17 ) x 60 = 2,580
( 60 - 12 ) x 39 = 1,872
( 60 - 7 ) x 13 = 689
( 60 - 2 ) x 5 = 290
o
36,056 F-Hr

16
T 60 oF 17 to 24 Hours
o
( 60 - 57 ) x 125 Hour = 375 F-Hr
( 60 - 52 ) x 159 = 1,272
( 60 - 47 ) x 179 = 2,327
( 60 - 42 ) x 188 = 3,384
( 60 - 37 ) x 253 = 5,819
( 60 - 32 ) x 307 = 8,596
( 60 - 27 ) x 213 = 7,029
( 60 - 22 ) x 133 = 5,054
( 60 - 17 ) x 81 = 3,483
( 60 - 12 ) x 59 = 2,832
( 60 - 7 ) x 20 = 1,060
( 60 - 2 ) x 6 = 348
o
41,579 F-Hr

Therefore: at 60 oF the T (Bin Hours) =

01 to 08 = 46,743

09 to 16 = 36,056

17 to 24 = 41,579

Total = 124,378 oF-Hr

17
 BIN HOUR MULTIPLIER OR THE PERCENTAGE OF EACH SHIFT OF EACH
TEMPERATURE

EXAMPLE:
1. First Shift or 01 to 08 at 70oF occupied hour.
Monday through Friday:
A. Hours occupied = 8:00 a.m. to 8:30 a.m. = hour
Total hours of shift = 8 hours
Portion of shift occupied if 0.5 hours = 0.0625
8 hours

B. Days of the week = Monday through Friday = 5 days

Total days in a week = 7 days
Portion of the week occupied is = 5 Days = 0.7143
7 Days

C. Specific portion of shift for Monday through Friday

0.0625 x 0.714 = 0.0446

2. Second shift or 09-16 at 70oF occupied hours.

Monday through Friday:
A. Hours occupied = 8:30 a.m. to 4:30 p.m. = 8 hours
Total hours of shift = 8 hours
Portion of shift occupied if 8 hours = 1.000
8 hours

B. Days of the week = Monday through Friday = 5 days

Total days in a week = 7 days
Portion of the week occupied is = 5 Days = 0.7143
7 Days

C. Specific portion of shift for Monday through Friday

1.0 x 0.714 = 0.7143

18
3. Third shift or 17 to 24 at 70oF occupied hours.
Monday through Friday:
A. Hours occupied = 4:30 p.m. to 5:00 p.m. = hours
Total hours of shift = 8 hours
Portion of shift occupied if 0.5 hours = 0.0625
8 hours

B. Days of the week = Monday through Friday = 5 days

Total days in a week = 7 days
Portion of the week occupied is = 5 Days = 0.7143
7 Days

C. Specific portion of shift for Monday through Friday

0.0625 x 0.714 = 0.0446

T 70oF T 60oF
01 to 08 = 0.0446 01 to 08 = 0.9553
09 to 16 = 0.7143 09 to 16 = 0.2857
17 to 24 = 0.0446 17 to 24 = 0.9553

NOTE 1: The portion of the shift at 70oF and at 60oF adds up to one (1) complete shift.

Estimate the total heat loss over the heating season starting September 1 thru May 1
Q = H.L.M. x T (Bin Hour)
Where: Q = Btus
H.L.M. = 1 Btu/Hr-oF
T = (Bin Hour)

19
70oF
o
01 to 08 = 64,803 x 0.0446 = 2,892.8 FHr.
09 to 16 = 51,626 x 0.7143 = 36,876.4
17 to 24 = 58,809 x 0.0446 = 2,625.2

60oF
01 to 08 = 46,743 x 0.9554 = 44,656.3
09 to 16 = 36,056 x 0.2857 = 10,301.1
17 to 24 = 41,579 x 0.9554 = 39,722.9
TOTAL = 137,074.7 oFHr.

Therefore:
Q = 1 BTU x 137,074.7 oFHr.
o
FHr.

= 137,074.7 oFHr.

20
 CALCULATIONS FOR RUN TIME HOURS
The running time of a optimally sized boiler to provide the total heat needed to maintain the
building temperature.
A optimally sized boiler would have the same heat output at design conditions as the heat loss at
design conditions.
Q = H.L.M. x T (Bin Hour)
Where: Q = Btus
H.L.M. = 1 Btu/Hr-oF
T = Design temperature difference

For Rochester, New York

Indoor Temperature: 70oF
Outdoor Temperature: 0oF

Q = 1 BTU x (70 - 0oF) = 70 BTU

Hr-oF Hr.

Running Time = Total heat loss = 137,074.7

Boiler output 70 Btu/Hr.

Running Time = 1,958.2 Hours

Running time = Total heat loss = H.L.M. x T (Bin Hour)

Boiler output H.L.M. x T

21
It does not matter what the buildings actual heat loss is. It will cancel out in the equation. That is why a
heat loss multiplier of 1 BTU/ hour-oF was chosen.

The percentage of running time for the total heating season for a perfectly sized boiler is:
Heating season = September 1 to May 1
242 Days x 24 Hrs = 5,808 Hours
Days

% of Boiler run time = 1,958.2 = 0.337 or 33.7 %

5,808

The summation of Bin hours during September 1 to May 1 is approximately 5,086 hours. The reason for
the difference between the total Bin hours and the total season hours is that there are a few hours above
59oF during that period, and it is assumed that the boiler is locked-out above this temperature.

22
 THE EFFECT OF OVERSIZING A BOILER ON THE PERCENTAGE OF
BOILER RUN TIME

Equation for generating a graph:

% of run time for perfectly sized boiler

% of Run time =
1 + % of an oversized boiler

In other words, % of run time = 0.3371

1+%

Note 1. The more the boiler is oversized the longer the boiler will be idling.

Note 2. If there is not a set-back during the unoccupied hour and the building kept throughout the

heating season from Sept. 1 to May 1, the percentage of boiler run time will be as follows:

% of run time at constant 70 oF = 175,237 x 100 = 43.1 %

with an optimally sized boiler 70 x 5,808

23
 Total Annual Run Time versus Boiler % Size
Sept. 1 - May 1
50%

40%
Note: Occupied Hours: 70 oF
Percent of Run Time for Season

Mon. - Sun.: With no set-back

30%

20%

10%

0%
0% 100% 200% 300% 400% 500%
Boiler % Oversize
24
 Total Annual Run Time versus Boiler % Size
Sept. 1 - May 1
50%

o
Note: Occupied Hours: 70 F
40% Mon. - Fri.: 8:00 a.m. - 5:00 p.m.
With a setback of 60 oF after regular hours.
Percent of Run Time for Season

30%

20%

10%

0%
0% 100% 200% 300% 400% 500%
Boiler % Oversize
25
 OVERSIZED BOILER EQUATIONS

Oversize Pr oper Size

%Oversized =
Pr oper Size

Separating the variables

Oversize Pr oper Size

% =
Pr oper Size Pr oper Size

Oversize
% = 1
Pr oper Size

Carry the 1 over to the left-hand side of the equation

Oversize
( % + 1) =
Pr oper Size

Multiplying left-hand side by the proper size

Oversize = ( % + 1) Pr oper Size

Total Heat Loss

% of Running =
[ Pr oper Size ][Total Hours ]

If the boiler is oversized

Total Heat Loss

% of Running =
[Oversize ][Total Hours ]

26
 DETERMINING EFFICIENCY OF OVERSIZED BOILERS

Total Run Time versus Boiler Oversize

% %
Running Efficiency

Oversize

1)
a) Collect the gas bill for one year and sum the consumption.
b) From total consumption subtract the base load.
c) Using the consumption between September and May, divide by the
maximum output of the boiler.
d) Divide the hours between September 1st and April 30th by 5808.
This will give actual % of running.
e) From the graph, enter the % of running as a result of step (d) and
draw straight line to the curve.
f) Go straight down to Oversize axis to find oversize.
g) Solve Proper Size = Oversize
1+%
This gives the proper size of boiler base or the actual consumption
or
Dividing the proper size by 70 oF gives the actual Heat Loss Multiplier with
infiltration.

27
 Percentage of Boiler Full Load
Versus
Outdoor Air Temperature
In Rochester, N.Y.

100%
23 Hr
90%
72 Hr
80% 172Hr
PERCENTAGE OF FULL LOAD

247 Hr
70%
402 Hr
60%
625 Hr

50% 928 Hr

745 Hr
40%
566 Hr
30% 503 Hr

439 Hr
20%
364 Hr
10%

0%
2 7 12 17 22 27 32 37 42 47 52 57
o
OUTDOOR AIR TEMPERATURE ( F)

Heating Season: Sept. 1 - April 30

<----------------------------------------------------- 242 DAYS ------------------------------------------------->
28
 AN EMPIRICAL EQUATION TO DETERMINE EFFICIENCY ON
BOILERS AT DIFFERENT LOADS

The efficiency of a boiler depends on how it is loaded. In general, the more

closely the loading approaches full load, the higher will be the efficiency.

E = EMAX (1 - e-4.9L)

Where EMAX = Optimum efficiency (around 0.80)

L = Load factor = actual output
maximum output
e = Base of natural logarithm (= 2.718 ...)

Example with 43.1% Load

Efficiency of a boiler with a maximum output of 100,000 BTUH but an actual

output of 43,100 BTUH (43.1% of the maximum load)

43,100
4.9( )
E = 0.801 e 100,000


E = 70.3%

Example with 97.14% Load

Efficiency of a boiler with a maximum output of 100,000 BTUH but an actual

output of 97,140 BTUH (97.14% of the maximum load)

97,140
4.9( )
E = 0.801 e 100,000


E = 79.3%

29
Niagara
Niagara Falls,
Falls, NY
NY Climatological
Climatological Data
Data
 MONTHLY BIN HOURS
September
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 47 32 50 129

50 - 54 45 12 36 93

45 - 49 32 2 19 53

40 - 44 18 0 5 23

35 - 39 5 0 1 6

30 - 34 1 0 0 1

25 - 29

20 - 24

15 - 19

10 - 14

5- 9

4- 0
148 46 111 305

30
October
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 24 42 34 100

50 - 54 43 47 50 140

45 - 49 51 38 56 145

40 - 44 48 15 38 101

35 - 39 35 7 21 63

30 - 34 17 1 4 22

25 - 29 2 0 1 3

20 - 24

15 - 19

10 - 14

5- 9

4- 0
220 150 204 574

31
November
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 10 21 12 43

50 - 54 18 26 26 70

45 - 49 28 34 34 96

40 - 44 41 45 42 128

35 - 39 52 43 48 143

30 - 34 48 35 40 123

25 - 29 26 8 21 55

20 - 24 8 6 6 20

15 - 19 3 1 3 7

10 - 14 2 0 1 3

5- 9

4- 0
236 219 233 688

32
December
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 0 5 1 6

50 - 54 4 5 4 13

45 - 49 6 8 10 24

40 - 44 20 29 19 68

35 - 39 37 49 46 132

30 - 34 62 65 63 190

25 - 29 47 34 42 123

20 - 24 28 25 25 78

15 - 19 21 19 21 61

10 - 14 15 7 14 36

5- 9 7 2 2 11

4- 0 1 0 1 2
248 248 248 744

33
January
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 0 0 0 0

50 - 54 2 2 2 6

45 - 49 4 6 3 13

40 - 44 6 7 7 20

35 - 39 16 24 24 64

30 - 34 45 51 46 142

25 - 29 40 58 50 148

20 - 24 42 46 38 126

15 - 19 39 24 33 96

10 - 14 28 20 28 76

5- 9 19 7 12 38

4- 0 6 2 2 10
247 247 245 739

34
February
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 0 1 0 1

50 - 54 1 4 4 9

45 - 49 3 7 2 12

40 - 44 7 14 10 31

35 - 39 18 33 27 78

30 - 34 52 64 58 174

25 - 29 44 43 47 134

20 - 24 37 26 33 96

15 - 19 23 11 15 49

10 - 14 20 12 17 49

5- 9 12 4 6 22

4- 0 5 3 3 11
222 222 222 666

35
March
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 2 4 4 10

50 - 54 2 12 3 17

45 - 49 5 23 11 39

40 - 44 13 36 22 71

35 - 39 32 56 49 137

30 - 34 78 52 72 202

25 - 29 54 41 47 142

20 - 24 35 13 29 77

15 - 19 18 5 9 32

10 - 14 6 1 1 8

5- 9 1 0 0 1

4- 0 0 0 0 0
246 243 247 736

36
April
Hours Hours Hours
Temperature Range 01-08 09-16 17-24 Total

55 - 59 13 38 24 75

50 - 54 22 35 34 91

45 - 49 38 39 44 121

40 - 44 44 35 45 124

35 - 39 59 26 37 122

30 - 34 42 8 24 76

25 - 29 14 1 5 20

20 - 24 2 1 2 5

15 - 19 2 0 0 2

10 - 14 0 0 0 0

5- 9 0 0 0 0

4- 0 0 0 0 0
236 183 215 636

37
 HEATING BIN HOURS
LATITUDE: 43-06N LONGITUDE: 78-57W Niagara Falls, IAP New York

Temp January February March April May June July

Range Shift Shift Shift Shift Shift Shift Shift
Total Total Total Total Total Total Total
+5F A B C A B C A B C A B C A B C A B C A B C
95 0 0 0 0 0 0 0
90 0 0 0 0 0 3 3 7 1 8
85 0 0 0 0 1 1 17 3 20 35 9 44
80 0 0 0 1 1 6 2 8 1 36 13 50 2 62 26 90
75 0 0 0 4 4 22 5 27 8 47 23 78 14 67 46 127
70 0 0 0 9 3 12 3 34 11 48 22 55 46 123 52 47 66 165
65 0 0 1 1 1 17 6 24 13 38 27 78 46 42 56 144 74 23 59 156
60 0 1 1 3 1 4 5 26 16 47 23 42 34 99 59 24 48 131 61 7 31 99
55 0 1 1 2 4 4 10 13 38 24 75 35 35 42 112 46 12 31 89 33 9 42
50 2 2 2 6 1 4 4 9 2 12 3 17 22 35 34 91 43 36 45 124 41 5 15 61 12 1 13
45 4 6 3 13 3 7 2 12 5 23 11 39 38 39 44 121 55 23 47 125 15 1 5 21 1 1
40 6 7 7 20 7 14 10 31 13 36 22 71 44 35 45 124 46 10 27 83 2 2 0
35 16 24 24 64 18 33 27 78 32 56 49 137 59 26 37 122 25 2 8 35 0 0
30 45 51 46 142 52 64 58 174 78 53 72 203 42 8 24 74 7 1 8 0 0
25 40 58 50 148 44 43 47 134 54 41 47 142 14 5 19 0 0 0
20 42 46 38 126 37 26 33 96 35 13 29 77 2 1 2 5 0 0 0
15 39 24 33 96 23 11 15 49 18 5 9 32 2 2 0 0 0
10 28 20 28 76 20 12 17 49 6 1 1 8 0 0 0 0
5 19 7 12 38 12 4 6 22 1 1 0 0 0 0
0 6 2 2 10 5 3 3 11 0 0 0 0 0
-5 1 1 2 2 0 0 0 0 0
-10 0 0 0 0 0 0 0
-15 1 1 0 0 0 0 0 0
38
 HEATING BIN HOURS
LATITUDE: 43-06N LONGITUDE: 78-57W Niagara Falls, IAP New York
Tem
August September October November December TOTALS
p
Shift Shift Shift Shift Shift Shift
Ran Total Total Total Total Total Total
A B C A B C A B C A B C A B C A B C
ge
95 0 1 1 0 0 0 0 1 0 1
90 5 5 3 3 0 0 0 0 18 1 19
85 19 3 22 9 2 11 0 0 0 0 81 17 98
80 49 15 65 17 5 22 1 1 2 2 0 4 174 61 239
75 1 68 41 123 3 29 15 47 7 1 8 5 2 7 0 39 249 133 421
70 14 62 66 167 22 40 27 89 1 17 3 21 4 13 5 22 1 1 143 278 227 648
65 39 31 65 168 31 52 37 120 11 31 15 57 10 21 12 43 5 1 6 258 261 278 797
60 72 12 38 105 35 44 44 123 16 44 26 86 18 26 26 70 4 5 4 13 276 234 268 778
55 55 3 18 68 47 32 50 129 24 42 34 100 28 34 34 96 6 8 10 24 281 209 256 746
50 47 3 19 45 12 36 93 43 47 50 140 41 45 42 128 20 29 19 68 288 227 254 769
45 16 5 32 2 19 53 51 38 56 145 52 43 48 143 37 49 46 132 298 231 281 810
40 5 0 18 9 27 48 15 38 101 48 35 40 123 62 65 63 190 294 217 261 772
35 0 5 1 6 35 7 21 63 26 8 21 55 47 34 42 123 263 190 230 683
30 0 1 1 17 1 4 22 8 6 6 20 28 25 25 78 278 208 236 722
25 0 0 2 1 3 3 1 3 7 21 19 21 61 178 162 174 514
20 0 0 0 2 1 3 15 7 14 36 133 93 117 343
15 0 0 0 0 7 2 2 11 89 42 59 190
10 0 0 0 0 1 1 2 55 33 47 135
5 0 0 0 0 0 32 11 18 61
0 0 0 0 0 0 11 5 5 21
-5 0 0 0 0 0 3 0 0 3
-10 0 0 0 0 0 0 0 0 0
-15 0 0 0 0 0 1 0 0 1
39
 BIN HOUR SUMMATION FROM SEPT. 1 TO MAY 1.
BIN TEMP 01 TO 08 09 TO 16 17 TO 24 TOTAL
100 118719 110675 98492 327886
99 116916 108950 96933 322799
98 115113 107225 95374 317712
97 113310 105500 93815 312625
96 111507 103775 92256 307538
95 109704 102050 90697 302451
94 107901 100325 89138 297364
93 106098 98600 87579 292277
92 104295 96875 86020 287190
91 102492 95150 84461 282103
90 100689 93425 82902 277016
89 98886 91700 81343 271929
88 97083 89975 79784 266842
87 95280 88250 78225 261755
86 93477 86525 76666 256668
85 91674 84800 75107 251581
84 89871 83075 73548 246494
83 88068 81350 71989 241407
82 86265 79625 70430 236320
81 84462 77900 68871 231233
80 82659 76175 67312 226146
79 80856 74450 65753 221059
78 79053 72725 64194 215972
77 77250 71000 62635 210885
76 75447 69275 61076 205798
75 73644 67550 59517 200711
74 71841 65825 57958 195624
73 70038 64100 56399 190537
72 68235 62375 54840 185450
71 66432 60650 53281 180363
70 64629 58925 51722 175276
69 62826 57200 50163 170189
68 61023 55475 48604 165102
67 59220 53750 47045 160015
66 57417 52025 45486 154928
65 55614 50300 43927 149841
64 53811 48575 42368 144754
63 52008 46850 40809 139667
62 50205 45125 39250 134580
61 48402 43400 37691 129493
60 46599 41675 36132 124406
59 44796 39950 34573 119319
58 42993 38225 33014 114232
57 41190 36500 31455 109145
56 39483 34900 30039 104422
55 37776 33300 28623 99699
54 36069 31700 27207 94976
53 34362 30100 25791 90253
52 32655 28500 24375 85530
51 31085 27059 23102 81246
50 29515 25618 21829 76962

40
 BIN HOUR SUMMATION FROM SEPT. 1 TO MAY 1.
BIN TEMP 01 TO 08 09 TO 16 17 TO 24 TOTAL
50 29515 25618 21829 76962
49 27945 24177 20556 72678
48 26375 22736 19283 68394
47 24805 21295 18010 64110
46 23402 20033 16894 60329
45 21999 18771 15778 56548
44 20596 17509 14662 52767
43 19193 16247 13546 48986
42 17790 14985 12430 45205
41 16584 13911 11495 41990
40 15378 12837 10560 38775
39 14172 11763 9625 35560
38 12966 10689 8690 32345
37 11760 9615 7755 29130
36 10808 8795 7058 26661
35 9856 7973 6361 24190
34 8904 7152 5664 21720
33 7952 6331 4967 19250
32 7000 5510 4270 16780
31 6393 4496 3850 14739
30 5786 4482 3430 13698
29 5179 3968 3010 12157
28 4572 3454 2590 10616
27 3965 2940 2170 9075
26 3585 2639 1935 8159
25 3205 2338 1700 7243
24 2825 2037 1465 6327
23 2445 1736 1230 5411
22 2065 1435 995 4495
21 1837 1267 877 3981
20 1609 1099 759 3467
19 1381 931 641 2953
18 1153 763 523 2439
17 925 595 405 1925
16 803 508 347 1658
15 681 421 289 1391
14 559 334 231 1124
13 437 247 173 857
12 315 160 115 590
11 264 134 97 495
10 213 108 79 400
9 162 82 61 305
8 111 56 43 210
7 60 30 25 115
6 48 24 20 92
5 36 18 15 69
4 24 12 10 46
3 12 6 5 23
2 0 0 0 0

41